Roaster

ABSTRACT

A roaster includes an upper pan including an upper side wall and an upper pan heating element inside the upper tub. The roaster further includes a lower pan connected to the upper tub, the lower pan including a lower side wall and a lower pan heating element inside the lower tub. An upper pan fixed temperature regulator and a lower pan fixed temperature regulator may be preset to different selected temperatures. The roaster may also include a grease drain opening through the lower tub. Temperature and timer control logic are provided for the upper pan heating element and the lower pan heating element. In order to set cooking time, the roaster includes a control interface that includes, in one embodiment, a time increment button and a time decrement button.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is based on Provisional Patent Application No.60/347,531, filed Jan. 10, 2002.

BACKGROUND OF THE INVENTION

[0002] This invention relates to devices for coolking food. Inparticular, this device relates to a contact roaster.

[0003] When cooking a large food item such as a chicken, duck, or potroast, a cook must turn to a high capacity cooking device. In the past,high capacity cooking devices including, as examples, roaster ovens,slow cookers, and oven broilers have attempted to meet this need. Each,however, has its drawbacks.

[0004] For example, a conventional oven broiler is fixed in place,unwieldy to operate, and difficult to clean. Slow cookers are oftenportable, but typically heat food unevenly, particularly when theyincorporate a glass cover. Prior roaster ovens typically providedheating elements limited in number and position, while requiring acomplex mechanical assembly for rotating food past the heat elements.The heat elements were often exposed, leading to inadequate heatintensity for cooking the food item and failing to seal in juices.Instead, the food dried out significantly delring cooling. Furthermore,grease drainage can be inadequate and messy, often leaving the food itemto cook in its own grease.

[0005] A need has long existed in the industry for a roaster thataddresses the problems noted above and others previously experienced.

BRIEF SUMMARY OF THE INVENTION

[0006] One embodiment of the roaster includes an upper pan including anupper side wall and an upper pan heating element inside the upper pan.The roaster further includes a lower pan connected to the upper tub, thelower pan including a lower side wall and a lower pan heating elementinside the lower pan. A hinge may be used to connect the lower pan tothe upper pan.

[0007] The roaster may include: an upper pan fixed temperature regulatorand a lower pan fixed temperature regulator. The upper pan fixedtemperature regulator may be preset to a first selected temperature, andthe lower pan fixed temperature regulator may be preset to a secondidentical or different selected temperature. The temperature regulatorsmay be thermostats, for example, although other temperature sensing orfeedback mechanisms are also suitable. The roaster may also include agrease drain opening through the lower pan. A grease tray positionedunderneath the opening could collect grease draining from food beingcooked.

[0008] The electrical system of the roaster includes timer controlcircuitry and temperature control circuitry that is coupled to the upperpan heating element and the lower pan heating element. The temperaturecontrol circuitry or the timer control circuitry may be implemented, forexample, using a microcontroller coupled to a memory (or with onboardmemory) which stores instructions for execution by the microcontroller.A time display coupled to the timer control circuitry may also beprovided. The time display shows, as examples, the amount of timeremaining in an initial pre-heat cycle or the cooking time remaining forthe food in the roaster. In order to set cooking time, the roasterincludes a control interface that includes, in one embodiment, a timeincrement button and a time decrement button. Other implementations,methods, features and advantages of the invention will be or will becomeapparent to one with skill in the art upon examination of the followingfigures and detailed description, It is intended that all suchadditional systems, methods, features and advantages be included withinthis description, be within the scope of the invention, and be protectedby the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 shows a perspective view of one potential embodiment of theroaster in the closed position.

[0010]FIG. 2 illustrates top-down view of the roaster of FIG. 1 in theclosed position.

[0011]FIG. 3 is a front elevational view of the roaster of FIG. 1 in theopen position.

[0012]FIG. 4 is a perspective view of the roaster of FIG. 1 in the openposition.

[0013]FIG. 5 is a side elevational view of the roaster of FIG. 1 in theopen position.

[0014]FIG. 6 shows a side view of the handle on the upper pan.

[0015]FIG. 7 is a bottom plan view of the upper pan of the roaster ofFIG. 1.

[0016]FIG. 8 is a side cross-sectional view of the upper pan of FIG. 7.

[0017]FIG. 9 is a top cross-sectional view of the upper pan of FIG. 7.

[0018]FIG. 10 is a top plan view of the lower pan of the roaster of FIG.1.

[0019]FIG. 11 is a cross-sectional view of the lower pan of FIG. 10taken along section lines A-A.

[0020]FIG. 12 is a cross-sectional view of the lower pan of FIG. 10taken along section lines B-B.

[0021]FIG. 13 is a front elevational view of the lower pan of theroaster of FIG. 1.

[0022]FIG. 14 illustrates a perspective view of the casserole tray as ithas been inserted to the lower pan of the roaster of FIG. 1.

[0023]FIGS. 15a, 15 b and 15 c, show the top plan front elevational andside elevational views of the casserole tray of FIG. 14.

[0024]FIG. 16 depicts a wiring diagram for the roaster of FIG. 1.

[0025]FIG. 17 is a schematic diagram of the wiring for one potentialembodiment of the temperature control circuitry.

[0026]FIG. 18 shows a schematic diagram for one potential embodiment ofthe timer control circuitry.

[0027]FIG. 19 shows a flow diagram for the firmware in one potentialembodiment of the timer control circuitry.

[0028]FIG. 20 presents a front elevational view of the roaster of FIG. 1in the closed position.

[0029]FIG. 21 shows a side elevational view of the roaster of FIG. 1 inthe closed position.

[0030]FIG. 22 presents a top plan view of the roaster of FIG. 1 in theclosed position.

[0031]FIG. 23 shows a perspective view of the roaster of FIG. 1.

[0032]FIG. 24 illustrates a back elevational view of the roaster of FIG.1.

DETAILED DESCRIPTION OF THE INVENTION

[0033]FIGS. 1 and 23 show perspective views of the roaster 100 in aclosed configuration. The roaster 100 includes a lid 102, a base 104,and may include a drip pan 106 (FIG. 1). A time control operatorinterface 108 is provided. Casserole pan handles 110 and 112 for theoptional casserole pan are also visible in FIG. 1.

[0034] A handle 114 is attached to the lid 102 to allow an operator toeasily open and close the roaster 100. The handle 114 also incorporatesthe operator interface 108. The operator interface 108 includes a timedisplay 116 (e.g., a 2.5 digit seven segment display), a time incrementbutton 118, a time decrement button 120, an on/off indicator 122 (e.g.,a light emitting diode), and an on/off switch 124 (e.g., a two positionrocker switch). Other switch types (such as momentary contact and slideswitches) may be utilized as well as other types of displays such as aplurality of LCDs or an LCD display for operator interface 10I.

[0035]FIG. 2 shows a top down view of the roaster 100. FIG. 3 is afrontal view of the roaster in its open configuration. In particular,FIG. 3 shows the upper pan 302 including the upper side wall 304.Similarly, a lower pan 402 including a lower side wall 404 (see FIG. 4)is present in the base 104. The lid 102, base 104, upper pan 302 andlower pan 402 are preferably oval shaped, although other shapes are alsosuitable (e.g., round). In one embodiment, the upper pan 302 and lowerpan 402 are formed from high pressure diecast aluminum with ananti-stick (e.g., Teflon) coating.

[0036]FIG. 4 also illustrates the grease drain opening 406, which isinside the lower pan 402 of roaster 100. Thus, grease may drain whilethe roaster is in the closed cooking position. The drip pan 106 (see,e.g., FIGS. 1 and 2) slides into a recess underneath the lower pan 402such that it can be situated under the grease drain opening 406.Preferably, the drip pan 106 slides freely underneath the roaster 100,although in other embodiments, the drip pan 106 may lock into place, orslide on guide rails, or the like.

[0037] The upper pan 302 and lower pan 402 provide a large cookingvolume in which to cook large food items. Thus, rather than flat platesthat are suitable for limited purposes (e.g., thin hamburgers, chickenbreast patties, grilled cheese sandwiches and the like), the upper pan302 and lower pan 402 form a volume that allows the operator to cookwhole chickens, roasts, and the like. In one embodiment, the upper pan302, lower pan 402, with their respective upper side wall 304 and lowersidewall 404 provide an enclosed cooking volume of approximately 3.9quarts, although the pans 302 and 402, and sidewalls 304 and 404 may bevaried in size to meet other volumes.

[0038]FIG. 5 shows a side view of the roaster in its open configuration.From this view it can be seen that in the embodiment depicted in thisapplication, the hinge 502 connects the lid 102 to the base 104. Otheropening and closing mechanisms may be used in place of the hinge 502,however. The roaster 100 is thus opened by lifting on the lid 102 (andin particular, the handle 114).

[0039]FIG. 6 shows a side view of the handle 114. As noted above, thehandle 114 is attached to the lid 102. The handle 114 preferablyincludes the ridge 602 and the shield 604. The ridge 602 provides aconvenient surface for application of force to open the roaster. Theshield 604 provides a finger rest between the handle 114 and the lid102.

[0040]FIGS. 7-9 show various views of the upper pan 302. As shown, forexample, in FIG. 9, the upper pan 302 includes an embedded heatingelement 902 and thermostat 904. The heating elements and thermostatsembedded in the upper pan 302 and lower pan 402 of the roaster 100 willbe discussed in more detail below with regard to the electrical systemof the roaster. It is not necessary for the heating elements andthermostats to be embedded in either pan. Rather, they merely need to bethermally associated with their respective pans so that they can raiseand sense the relative temperature of their associated pans,respectively. It is noted, however, that embedding the heating elementsin the metal (e.g. diecast aluminum) produces greater heat intensityfrom the upper and lower pans 302, 402, and the upper and lowersidewalls 304, 404 than using separate free standing heat elements. As aresult of the embedded heating elements, the roaster 100 moreeffectively seals in juices, wlile providing intense heat for cookingfrom all directions around the food. Tlnus, the roaster 100 does notsimply provide planar heating (e.g., from a top plate and a bottomplate). Rather, the roaster 100 provides cooling heat around theentirety of the food being cooked.

[0041] In most instances, the food will generally be in direct contactwith the lower pan 402 (due to gravity) but not the upper pan 302. Forthat reason, as will be described in more detail below, the roaster 100preferably regulates the temperature of the upper pan 302 to a highertemperature than that of the lower pan 402. For example, the upper pan302 may be set 20-100 degrees C. higher than the lower pan 402.

[0042] The roaster 100 may optionally support, in the upper pan 302, ananti-stick coated aluminum or steel insert that lowers the effectiveheight of the upper sidewall 304. FIG. 8 shows an insert 802 across theupper pan 302. The insert 802 may conform to the shape of the upper pan302 in much the same way that the casserole pan 1402 (discussed belowwith reference to FIG. 14) conforms to the shape of the lower pan 402.The insert 802 may snap or lock into place as an interference fit withthe upper pan 302, or by using a latching or retaining mechanism (e.g.,a screw or bolt) in the upper pan 302 or on the upper sidewall 304. Bylowering the effective height of the upper sidewall 304, the operator,if desired, may provide direct heating contact on both the top andbottom surfaces of the food.

[0043]FIGS. 10-13 are various views of the lower pan 402. As shown inFIG. 11, for example, the lower pan 402 includes an embedded heatingelement 1108, and preferably ribs 1104 and valleys 1106 (see also FIGS.4 and 10). The ribs 1104 and valleys 1106 help grease to drain fromunder the food being cooked so that the grease may flow down the lowerpan 402—which is preferably inclined at a slight angle—toward the greasedrain opening 406 and out of the lower pan, as shown in FIGS. 10 and 11.FIG. 11 also shows a plurality of legs that raise the bottom of thelower pan 402 so as to minimize the possibility of scratching thekitchen counter.

[0044]FIG. 14 shows a perspective view of the base 104 and the casserolepan 1402 with handles 110 and 112. The casserole pan 1402 preferablysits in substantial contact with the lower pan 402 and lower sidewall404. The casserole pan 1402 is preferably formed from anti-stick, coatedaluminum or steel. FIGS. 15a, 15 b and 15 c provide additional views ofthe casserole pan 1402.

[0045] The casserole pan 1402 is heated by the lower pan 402 and lowersidewall 404, but also receives heat from the upper pan 302 and theupper sidewall 304. The casserole pan 1402 provides a convenient dish inwhich food may be both baked and served.

[0046] Table 1, below, provides a sumniary of characteristics for oneembodiment of the roaster 100. TABLE 1 Total capacity 3.9 Quarts (3.7liter) Cooking pan capacity 1.8 Quarts (1.7 liter) Lid capacity 2.1Quarts (2.0 liter) Internal Height (closed) 4″-4.4″ (100-110 mm)External Height (closed) 8.9″ (225 mm) Internal Length × width 9.9″ ×8.1″ (250 mm × 205 mm) External Length × width 11.5″ × 11.2″ (290 mm ×283 mm) Drip Tray capacity 0.35 quarts (0.33 liter) Drip Tray dimensions(L × W × H) 6.3″ × 5.9″ × 1″ (160 mm × 150 mm × 25 mm) Casserole pandimensions 7.9″ × 9.9″ × 2″ (L × W × H) (200 mm × 250 mm × 50 mm)Dimension across casserole 13.8″ (350 mm) pan-handles Voltage input 240VAC or 120 VAC Power switch On/Off with LED indicator Element wattage1400 Watt Current draw 5.8 Amps @ 240 VAC 11.7 Amps @ 120 VACTemperature control Automatic fixed temperature thermostats in lid andbase Over temperature safety 1 one shot thermal fuse in lid Maximumoperating temperature 302 degrees F. in base and 410 degrees F. in lid(150 degrees C. and 210 degrees C.) Timer 3 digit display of elapsedtime with warning buzzer Time set Up/Down buttons Handle MaterialPolypropylene External body and cover material Painted Phenolic Upperand Lower pan Material High pressure diecast aluminum Teflon coating oninternal surfaces Casserole pan material Teflon coated aluminum/steelCable Permanently wired to unit with plug

[0047]FIG. 16 shows one potential wiring diagram for the roaster 100.The wiring diagram includes the wiring harness 1600 and temperaturecontrol circuitry. The temperature control circuitry includes the upperheating element 902 and upper thermostat 904, as well as the lowerheating element 1108 and the lower thermostat 1602. An on/off switch1604 for the roaster 100 is also shown. Table 2, below, summarizescharacteristics of the thermostats and heating elements. TABLE 2 Upperheating element 120 V, 550 W Lower heating element 120 V, 550 W Upperthermostat Opening Temperature: 195 degrees C. ± 9 degrees C. ClosingTemperature: 175 degrees C. ± 11 degrees C. 120/250 VAC, 10 A Lowerthermostat Opening Temperature: 150 degrees C. ± 9 degrees C. ClosingTemperature: 135 degrees C. ± 11 degrees C. 120/250 VAC, 10 A

[0048]FIG. 16 also shows a spring 1605. The spring is a nickel platedmild steel spring tube that protects the wiring harness where it exitsthe base 104 and enters the lid 102.

[0049]FIG. 17 is one potential wiring diagram 1700 for the roaster,including the temperature control circuitry. The rocker switch 1604serves as an on/off switch. The wiring diagram is divided between theupper pan 302 and the lower pan 402. The upper pan 302 includes theupper heating element 902 and the upper thermostat 904, a fuse 1702(e.g., a 250V, 10 A or 120V, 15 A fuse), and a timer circuit board 1704.The lower pan 402 includes the lower heating element 1108 and the lowerthermostat 1602.

[0050] When an operator switches on the roaster 100, the thermostats904, 1602 close to initiate heating of the heating elements 902, 1108.When the heating elements 902, 1108 reach a preselected temperature (assensed by the thermostats 904, 1602), the thermostats 904, 1602 open toprevent additional heating of the heating elements 902, 110S. As notedabove, the thermostats may be set to provide different temperaturecontrol for the upper pan 302 and the lower pan 402.

[0051]FIG. 18 shows one potential implementation of timer controlcircuitry 1800 present on the timer circuit board 1704. The timercontrol circuitry 1800 includes a microcontroller 1802 coupled to thetime display 116 (e.g., a 2.5 digit seven segment display) and a controlinterface that includes a time increment button 118 and a time decrementbutton 120. The power indicator 122 illuminates when the roaster isconnected to an AC line voltage, and extinguishes when the connection isremoved, whifle the buzzer 1804 provides an audible alarm or alert tothe operator. The timer control circuitry 1800 uses the AC linefrequency as a time base. The timer control circuitry 1800, as shown,provides a programmable count down tinier that supports an operatoradjustable countdown time between 1 minute and 150 minutes.

[0052] When an operator switches on the roaster 100, the roaster 100preferably enters a pre-heat countdown state under control of firmwarein the microcontroller 1802. During the pre-heat countdown, thetemperature control circuitry heats the upper pan and lower pan heatingelements 902, 1108 under control of the upper and lower pan temperatureregulators (e.g., the thermostats 904, 1602). The upper pan 302 andlower pan 402 reach the selected temperatures during the pre-heatcountdown. As an example, a pre-heat countdown of 5-8 minutes may beprovided, followed by activation of the buzzer 1804 to alert thatoperator that the pre-heat period has ended.

[0053] At the end of the pre-heat countdown, the microcontroller 1802switches the roaster into an ON state. In the ON state, themicrocontroller 1802 is responsive to the control interface. Theoperator may thereby use the tinme increment button 118 and timedecrement button 120 to set and adjust a time value (e.g., in minutes).In one implementation, incrementing a time value that is already maximum(e.g., 150 minutes) will set the time value to a minimum time value(e.g., 1 minute). Similarly, decrementing the minimum time value willset the time value to the maximum time value. Furthermore, holding thetime increment or time decrement button will increment or decrement thetime value at a predetermined rate (e.g., 10 increments or decrementsper second).

[0054] The time value represents the amount of time that remains beforean alarm is generated for the operator. The microcontroller 1802 countsdown the time value and updates the display accordingly. Once the timevalue has expired, the buzzer preferably alerts the operator (e.g., bybeeping 4 times with a 1 second on and 0.5 second off cadence). In oneimplementation, pressing any button while the buzzer is beeping willturn off the buzzer.

[0055]FIG. 19 presents a flow diagram of the operation of the firmwarein the microcontroller 1802. After reset, the microcontroller performsthe pre-heat countdown (step 1902). When the pre-heat countdown isfinished, the microcontroller 1802 activates the buzzer 1804 (step1904). Subsequently, the microcontiroller 11802 monitors the controlinterface to set the time (step 1906). The microcontroller 1802 countsdown the time (step 1908), and checks to see if time has expired (step1910). If so, then the microcontroller 1802 activates the buzzer 1912.In either case, the microcontroller returns to determine whether theoperator is adjusting the time using the control interface.

[0056]FIGS. 20-24 present additional views of the roaster 100. Inparticular, FIG. 20 shows a front view of the roaster 100, FIG. 21 showsa side view of the roaster 100, FIG. 22 shows a top down view of theroaster 100, FIG. 23 shows a perspective view of the roaster 100, andFIG. 24 shows a back view of the roaster 100. While the invention hasbeen described with reference to one or more preferred embodiments,those skilled in the art will understand that changes may be made andequivalents may be substituted without departing from the scope of theinvention. In addition, many modifications may be made to adapt aparticular step, structure, or material to the teachings of theinvention without departing from its scope. Tierefore, it is intendedthat the invention not be limited to the particular embodimentdisclosed, but that the invention will include all embodiments fallingwithin the scope of the appended claims.

1. A roaster comprising: an upper pan including an upper side wall; anupper pan heating element thermally associated with the upper pan; alower pan connected to the upper pan, the lower pan including a lowerside wall; and a lower pan heating element thermally associated with thelower pan.
 2. The roaster according to claim 1, further comprising: anupper pan fixed thermostat disposed in thermal association with theupper pan and operably coupled to the upper pan heating element; and alower pan fixed therrostat disposed in thermal association with thelower pan and operablv coupled to the lower pan heating element.
 3. Theroaster according to claim 2, wherein the upper pan fixed thermostat ispreset to a first selected temperature and the lower pan fixedthermostat is preset to a second selected temperature.
 4. The roasteraccording to claim 3, wherein the first selected temperature isdifferent than the second selected temDerature.
 5. The roaster accordingto claim 1, further comprising a grease drain opening through the lowerpan.
 6. The roaster according to claim 1, further comprising temperaturecontrol circuitry operably coupled to the upper pan heating element andthe lower pan heating element.
 7. The roaster according to claim 1,further comprising timer control circuitry operably coupled to the upperpan heating element and the lower pan heating element.
 8. The roasteraccording to claim 7, further comprising a time display operably coupledto the timer control circuitry.
 9. The roaster according to claim 7,further comprising a time control operator interface.
 10. The roasteraccording to claim 9, wherein the time control operator interfaceincludes user input to adjust the time.
 11. The roaster according toclaim 7, wherein the timer control circuitry comprises a power linefrequency timer.
 12. The roaster according to claim 1, wherein the lowerpan is hingedly connected to the upper pan.